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Transformers are among the expensive assets used by industries in an electrical system. Usually replacement of transformer costs more than transformers repairing services. To compensate the cost, manufacturers bring the option of remanufacturing or restoring the transformers. Remanufacturing of transformers is the replacement of the faulty parts and equipments.

Repairing services offered by suppliers and manufacturers who are designing transformers for distinct customers are having resources, expert personnel, and equipment to instantly get the transformer unit back in service.

How manufacturers commence the process?

Transformer manufacturers start with the assessment of the transformer. They perform various tests and inspection to find all the defects in the unit. Once the defects are recognized, they start fixing them one by one.

They replace your transformer oil if it is very contaminated. They replace any broken part of the unit, and use genuine components made with quality materials. New windings and components are readily available at OEM’s store for installation. You can source these components and install them once the unit is dismantled.

Companies operate the unit throughout their system regardless of the location. Remanufacturing of transformers avoids the failure impact prior its occurrence and expand the lifecycle of the transformer at low cost and time.

Remanufacturing is different from repairing. If you have a transformer and it is not working, you can take it to the manufacturer’s facility. There experts will diagnose the entire unit and perform desired tests to avail the report of the unit. If you want to enhance any functionality, you can do it with the help of experts. This is remanufacturing.

If they just replace the damaged component and install the brand new or well-maintained used component to your unit, this process is known as repairing because they just installed the faulty part to your unit to make it functioning again.

Repairing of transformer includes working on its original electrical, mechanical, and thermal design. Whereas, restoration or remanufacturing is a different thing, you cannot take repairing as a light matter.

There are manufacturers across the world offering premium transformers repairing services. This post is about repairing the lamp of step down transformer at your own. This project will require the components of the lamp- bulb, transformer, and base. Apart from this, you will also require a soldering iron, power strip, and a little multipurpose tool used by technicians.

What’s inside the black box?

One of the lacking of the design of transformer lamp is the remote transformer inside a plastic box. The transformer is placed halfway between the ends of a power cord i.e. approx. 6 ft long. Transformer is a heavy component that the manufacturing company might have had a better design with reliable packaging. When the plastic case was unboxed, experts observed:

Damaged plastic black case

Step down coil with magnetic core

Fractured output connector

Primary side coil hardwired to AC power cord

Steps to Follow:

Remove the potting material and access the leads of the primary side coil

Electrical component manufacturers rapidly pot their products with non-conductive material. This offers robustness to the product and make it safer for consumer. Electrical devices are built with sensitive components and with potting, manufacturers make them immobilize. This further helps them in making the device more robust and resistant to mechanical shock and abrasion.

High voltages can be a safety hazard, so potting material’s electrical isolation property prevents accidental electrical short circuits that can result in fire incident, fatalities, or injuries.

Reconnecting the primary winding leads to the AC power cord

This is an additional step included in the troubleshooting process as the soldered connections may have been damaged by first step. Regardless of the time when leads were damaged or distorted, the connections were broken when inspected without potting material across the primary winding.

Apply power to the transformer and check proper operation

Output Connector Story

Inspection of the lamp’s transformer revealed the damaged done to the output connector. However, when you see from the outside, you won’t find any disorder, but initially the connector has been fractured. This makes transformer unable to perform and function properly. You can hire some technicians if you are unable to perform Transformers Repairing job your own.

Royal Transformers is offering qualified engineers assistance to help you in repairing transformers and their critical components. They can also help in restoring your transformer. Connect with them to avail more details.

Growing population and settling of number of industries in distinct countries generating huge requirement for electrical energy. Power transformers India manufacturing power transmitting equipments to meet electricity needs. It is not always used in the same place that it is produced, which means long-distance transmission lines and distribution systems are a must have product.

If you own any transformer and it is 10 to 15 years old, you have to take proactive steps to save maintenance and utility costs. There are rare cases of breakdown of power transformer. But when it happens, the results are devastating and instant. So, it is important for you to know the best upgrading process for your power transformer. Let’s discuss them-

Determining the robustness of transformer

Prior installation of transformer, you need to acknowledge yourself about the build, design and materials used for constructing a transformer. The common types of transformers are liquid filled and dry type transformers.

The liquid or oil filled transformer uses coolant or any other similar liquid whereas the dry type range of transformer uses air. Dry type range possesses less chance of fire and leakage risk. It is the coil of the transformer that affects the robustness. The best robust model has round disc-wound coil. These transformers stay cooler, run without noise, and offer less risk of short circuit and are energy efficient as compared to others.

The round design of the transformer is more reliable and efficient and this is why it consumes less electricity.

Money saving with remanufacturing

Just in case you are financially weak or you don’t want to spend more amount on new transformer, you can also think about remanufacturing. In case you are buying a reconditioned transformer, do ensure you buy it from a genuine vendor. There should be a complete rewinding of the primary and secondary coils and with brand new low and high voltage bus bars. You can keep the original core 90% of the time, and replace it occasionally because older steel offers less efficient performance as compared to modern core materials.

Royal Transformers Company offers power transformers in India and overseas. It has many international clients across the world. You can also avail custom range of transformers as per your requirement. Mail your all specifications and requirements to the experts and avail desired transformer product.

Transformer is not a mere device; it is a house of various components installed by power transformers exporters India. These components work together to transfer electricity from one circuit to another with electromagnetic induction. The device is used for stepping up or stepping down the voltage levels at domestic or business site. There are many parts that complete the design of a transformer. These basics components are made with precision material to provide long life and corrosion protection. Read this story further to know about the parts used in transformers.

Laminated core

Laminated core installed in a power transformer helps support the transformer windings. It also provides a low reluctance path to the magnetic flux flow. Laminated core are designed with soft iron core to lower the eddy current loss and Hysteresis loss.

The composition of transformer core relies on such factors like current, voltage, and frequency. Its diameter is directly proportional to copper loss and is inversely proportion to the Fe (iron) loss.

Windings

As you know, a power transformer has two windings- primary and secondary. Windings have several turns of copper coils bundled together and every bundle is connected in series to create a winding. You can also categorize them in two different ways- one is based on the input and output supply, other this based on voltage range.

The supply windings are primary and secondary ones. And voltage range windings are high voltage winding or low voltage winding.

Insulating materials

Card boards and insulating papers are used by manufacturers while constructing a transformer of to isolate primary and secondary winding from transformer core and from each other. You can also include transformer oil in the insulating materials list.

Transformer oil

There are two significant roles played by transformer oil. It is the insulation and cooling for the core and coil assembly. It is important to immerse the core and windings in the oil completely. Usually, hydrocarbon mineral oils are used by experts as transformer oil.

Oil contamination is a serious issue as it takes off the dielectric properties and make the transformer useless thing.

Conservator

It conserves the transformer oil. Conservator is an airtight metallic cylindrical drum that is equipped above the transformer. This component is connected to the main tank inside the transformer that is full of transformer oil.

So, these are some basic components installed in a transformer. There are a few more parts like cooling tubes, tap changer, explosion vent, etc. that are installed in every transformer device by power transformers exporters India. For more details about the design and model, contact the proficient expert manufacturers today.

Transformer oil is one the significant component in oil filled transformers. Transformers oil filtration experts determine the life expectancy and efficient performance of the transformer on the basis of the oil used in the device. The oil serves two critical functions :

It creates an acceptable level of insulation when combined with insulating materials used in the coils and conductors.

Transformer oil also serve the purpose of coolant that absorb heat from the core and the windings

Manufacturers use hydrocarbon mineral oil for transformer. The insulating oil is usually obtained by fractional distillation and successive treatment of crude petroleum. This is why it is known as mineral insulating oil. It preserves the winding and core as these are completely immersed in the oil and it prevents direct contact of oxygen present in environment with cellulose made paper insulation of windings as it is prone to oxidation.

Types of transformer oil used by experts-

There are two types of transformer oil used by engineers-

Paraffin based transformer oil

Naphtha based transformer oil

Naphtha is more likely to oxidize as compared to paraffin oil. However, the oxidation product that is sludge present in naphtha oil is more soluble than paraffin oil. This is why sludge of naphtha based oil is not gathered at the bottom of the device.

Paraffin based oil has disadvantages but still people use it for transformer due to its easy availability.

Dielectric strength of transformer oil is called breakdown voltage of transformer oil. To measure break down voltage of transformer oil, manufacturers provide a portable kit to the clients. In this kit, oil is kept in a pot in which a pair of electrodes is fixed with a gap of 2.5mm between them. In some kits, this gap can be 4mm.

Royal transformers manufacturers are providing effective and best transformer oil filtration services worldwide. You can anytime bring your transformer oil for testing to Royal Transformers team and get accurate results at decided timeline. This article was issued by the team of engineers to make you learn about the properties of transformer oil.

During the manufacturing and production process of electrical components and equipment like transformers, switch gears, etc. the use of insulating oils like mineral transformer oil is a must thing. The dialectical properties of mineral oil may differ on the basis of moisture, gas, suspended particles and other visible/invisible contaminants. Even when the oil is packed well, it absorbs some gas and moisture. This is why experts recommend reconditioning of oil prior using it for transformer.

Purification and treatment of oil is vital process as you need to expel the absorbed gas and moisture content from the oil to avoid premature failure of the transformer. Manufacturing units in the market are producing a variety of plants for the purification and reconditioning of the transformer oil. Such plants cater the range of low, medium, high, and extra high voltage equipments like transformers.

These manufacturing units and foundries always focus on the needs and specifications of the user and thus, all the plants are customized accordingly. The plants intended for the purpose of removing contaminants from the mineral oil perform certain operations-

Removal of suspended particles act like contaminants using filtering process

Degassing

Dehumidification

Flushing and cleaning of the device

De-acidification

What type of equipment manufacturing units are using to form plants?

There are total eight components that foundry engineers intend and design for making plant that treats mineral oil of the transformer.

Degassing chamber- it is a vacuum chamber intended with special packed columns to degas the oil. Degassing of oil can involve single or multiple stages in process.

Filters – These are easy to remove cartridge filters or back flushable edge filters used for filtering mineral oil. These cartridges are able to filter small to micron size particles in the oil.

This article is published in order to make you aware why on load/ on line transformer oil filtration is the best process to purify or treat your mineral oil of transformer. For feedback, you can make comments below. Thanks for your time.

There are plenty of reasons causing distribution transformer failure. Indian manufacturers take various steps as remedial measures in order to maintain transformers and keep them in working condition. We will read about those factors and remedial actions that Indian distribution transformers take at their units.

Vandalism – It is an action that deliberately damages the asset. Vandalism of distribution transformer occurs due to unsecured substation and lack of awareness among the public.

You can fix it by proper fencing and use gate with a lock if needed. Apply Danger plate in the substation and aware public through media and meetings.

Lack of testing – When you ignore regular testing of the transformer for any reason like non availability of earth tester, oil testing kit or anything else. When you are not taking regular ceck ups. When you are lacking in staff.

You can solve this issue by providing megger, tong tester, and earth tester in each sub division along with oil filter machine and oil testing kit. The schedules for testing transformer should be compiled and implemented. You can outsource the testing job.

Overrated fuses

It happens due to unavailability of rated fuse. And when field staff ignores the appropriate ratings of the fuse and use conductor as fuse.

You can fix it with prompt requisition and fuse procurement. You can provide training to the staff and tell them about using fuse, its correct size, and implications of overrating. It is important to not encourage them to use conductor as fuse wire.

Transformer burning

It happens due to leakage of oil at terminals. Short circuit could be another reason behind burning of the transformer.

You can save your transformer by proper tightening the terminal connections. You can also use apt size of lugs.

These are a few things causing transformer failure. Proficient engineers working in manufacturing units have just shared tips to treat the issues and save your transformer from sudden or premature failure. For more details, you can contact Indian distribution transformers makers.